Insulating Sealing Element for Head-of-Wall Joints

ABSTRACT

A sealing element for sealing a gap or joint between a support structure and a track is disclosed. The track includes a web and legs that extend vertically from the web. The sealing element includes a cover layer where the cover layer has a first portion that is adhesively attached to the support structure and a second portion that is adhesively attached to a leg of the track. The cover layer has a flexing point where the flexing point is disposed near a gap or joint between the support structure and the leg of the track.

This application claims the benefit of U.S. Provisional Application No. 62/026,993, filed Jul. 21, 2014, the disclosure of which is expressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention deals generally with the field of acoustical or firestopping insulation for head-of-wall joints, including, possibly, intumescent components.

In the building construction trade, a head-of-wall joint/gap (also sometimes referred to as a top-of-wall joint/gap) refers to the linear junction or interface existing between a top section of a framing or wallboard wall assembly and the ceiling, where the ceiling may be a next-level floor or corrugated/fluted pan roof deck, for example. A head-of-wall assembly is comprised of and defined by the following elements overhead structure, top of wall framing deflection system, fill, void, or cavity materials protecting any joints. Corrugated/fluted deck includes either floor or roof pan deck assemblies varying in flute size, height, and configuration. Concrete decks include post-tensioned slabs, poured in place concrete, and precast concrete units. Gypsum drywall ceilings are common fire rated assemblies.

Head-of-wall joints often present a serious challenge in terms of reducing or preventing the spread of smoke and fire during a building fire. In this regard and in common practice, a wall to ceiling connection of many newly constructed buildings consists essentially of metal framing assemblies. These metal framing assemblies are generally constructed from a plurality of metal framing members including studs, joints, trusses, and other metal posts and beams formed from sheet metal and frequently fabricated to have the same general cross-sectional dimensions as standard members used for similar purposes. Typical head-of-wall deflection systems include the following: “single long leg track”, which is a U-shaped track having typically longer legs, typically free floating studs, some type of bracing (CRC, flatstrap) to prevent rotation of studs; “double track”, which is a nested track configured of two U-shaped profiles, designed for screw attachment to brace studs without need for other bracing materials; “slotted track”, which is a U-shaped track having vertical slots located in the legs allowing for faster attachment through the slots, whereas screws keep the studs in place; and “slotted clips”, which are U-shaped tracks having pre-installed slotted clips that allow for attachment of fasteners through the slots, another way to attach the studs to eliminate dislodging. Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks. These C-shaped studs and U-Shaped studs may vary in their size, which, however, are standardized. The steel track (or channel) is configured to receive steel studs between the legs of the shaped channel. A wallboard is generally attached to at least one side of the studs. The studs and wallboard are in many instances spaced apart from the ceiling with a short gap distance in order to allow for ceiling deflections caused by seismic activity or moving overhead loads. Track and stud assemblies that allow for ceiling deflections are commonly referred to as dynamic head-of-wall systems. Exemplary steel stud wall constructions may be found in U.S. Pat. Nos. 4,854,096 and 4,805,364 both to Smolik, and U.S. Pat. No. 5,127,203 to Paquette. Exemplary dynamic head-of-wall systems having steel stud wall constructions may be found in U.S. Pat. No. 5,127,760 to Brady and U.S. Pat. No. 6,748,705 to Orszulak et al.

Firestops are thermal barrier materials or combinations of materials used for filling gaps and openings such as in the joints between fire-rated walls and/or floors of buildings. For example, firestops can be used in walls or floors to prevent fire and smoke from passing through the gaps or openings required for cables, pipes, ducts, or other conduits. Firestops are also used to fill joint gaps that occur between walls, between a ceiling and the head-of-wall joints.

So-called head-of-wall joints pose a number of challenges for the fireproofing industry. Walls are increasingly being made of gypsum wallboard affixed to a framework of metal studs capped by a horizontally extending track. Ceilings are increasingly being made by pouring concrete onto fluted steel. Although the distance between the horizontally extending tracks at the top of the wall is often fixed in relationship to the ceiling, the gypsum wallboards are subject to expansion and contraction due to motion of other building components, ground settling, or other causes. The joint, based on amount of deflection required, is designed and constructed to allow for vertical movement, allowing the wall to move independent of the structure, due to forces such as live/dead loading, thermal expansion/contraction, wind sway, or seismic movements. The head-of-wall joints allow vertical movement without damaging the wall or drywall. The drywall is the fire protection component and it's key that it's not damaged/cracked.

In order to contain the spread of smoke and fire, a fire resistant material such as, for example, mineral wool is often times stuffed into the gaps between the ceiling and wallboard (see, e.g., U.S. Pat. No. 5,913,788 to Herren). For example, mineral wool is often stuffed between a steel header track (e.g., an elongated U-shaped channel) and a corrugated steel roof deck (used in many types of steel and concrete building constructions); a fire resistant and generally elastomeric spray coating is then applied onto the exposed mineral wool to thereby form a fire resistant joint seal (see, e.g., U.S. Pat. No. 7,240,905 to Stahl). In certain situations where the ceiling to wallboard gap is relatively small, a fire resistant and elastomeric caulk is commonly applied so as to fill any small gaps. In still another approach and as disclosed in U.S. Pat. Nos. 5,471,805 and 5,755,066 both to Becker, a slidable non-combustible secondary wall member is fastened to an especially configured steel header track and immediately adjacent to the wallboard. In this configuration, the secondary wall member provides a fire barrier that is able to accommodate ceiling deflections. All of these approaches, however, are relatively labor intensive and thus expensive.

Intumescent materials have long been used to seal certain types of construction gaps such as, for example, conduit through-holes. In this regard, intumescent and fire barrier materials (often referred to as firestop materials or fire retardant materials) have been used to reduce or eliminate the passage of smoke and fire through openings between walls and floors and the openings caused by through-penetrations (i.e., an opening in a floor or wall which passes all the way through from one room to another) in buildings, such as the voids left by burning or melting cable insulation caused by a fire in a modern office building. Characteristics of fire barrier materials suitable for typical commercial fire protection use include flexibility prior to exposure to heat, the ability to insulate and/or expand, and the ability to harden in place upon exposure to fire (i.e., to char sufficiently to deter the passage of heat, smoke, flames, and/or gases). Although many such materials are available, the industry has long sought better and more effective uses of these materials and novel approaches for better fire protection, especially in the context of dynamic head-of-wall construction joints and gaps. The materials have the drawback that they are expensive.

Thus, and although construction joints and gaps are generally sealed in some manner (e.g., mineral wool and/or elastomeric coatings; see also, U.S. Patent Application No. 2006/0137293 to Klein), there are relatively few products and methods available that effectively and efficiently seal head-of-wall construction joints and gaps to thereby significantly enhance the ability of such joints and gaps to withstand smoke and fire penetration. In particular, there are very few products and methods available that address the needs for adequate fire protection and sealing of dynamic head-of-wall systems associated with steel stud wall constructions.

Recently more advanced head-of-wall fire block arrangements have been developed based on fire block header tracks. These fire block header tracks utilize an expandable fire-resistant material, such as an intumescent material, applied along a length of the header track of a wall assembly. The intumescent material is either positioned on the web of the header track, on the legs (hereinafter also referred to as flange) of the header track or alternatively wraps around a corner of the header track, extending both along a portion of a web of the header track and a flange of the header track. The intumescent material advantageously is held in place between the web of the header track and the floor or ceiling above the wall. When exposed to a sufficient temperature, the intumescent material expands to fill gaps at the head-of-wall. The portion of the intumescent trapped between the header track and the floor or ceiling ensures that the intumescent stays in place as it expands and does not become dislodged as a result of the expansion.

With the use of such fire-resistant material, the metal tracks often require a unique construction on the exterior surface of the metal track which can have a predefined area such as a recess or the like which identifies the specific location required for placement of such an intumescent and/or acoustic layer of insulation material. In particular, as the joint moves responsive to normal expansion and contraction of the building components, the insulating tape and/or the coatings of insulating material which is attached directly to the surfaces of flanges can become dislodged from components of the head-of-wall area, that is, particularly dislodging from the surfaces of the downwardly extending side sections of the track or runner. Also these systems do not specifically address variations in the contour or profile of the ceiling or roof area which comes into direct abutment with the upper portion of the metal track. Such variations in the configuration of the building construction in this area can form gaps between the track and the adjacent roof or ceiling area which are not adequately addressed for insulation by the above described prior art systems.

One of the advantages of the sealing strip of the present invention is that it is usable with conventionally OEM metal track construction and does not require any customized design for the ceiling runner.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to effectively seal between conventionally designed metal track sections and the immediately adjacent roof or ceiling area for firestopping and optionally acoustic insulating thereof.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to be usable with any joints and gaps between construction elements, preferably conventional steel framing and gypsum board wall constructions.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to be usable with floor or roof constructions of any conventional construction including solid concrete or a composite material installed atop a corrugated steel deck.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to prevent the spread of sound, noise, fire, super-heated gases, flames and/or smoke in these areas.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to provide more effective insulating by providing the insulating material just before the joint between the top of the metal track and the bottom of the support structure, e.g., overhead structure in case of a ceiling, to assure sealing against cold gases and smoke before the material provides a firestop at elevated temperatures.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to minimize costs and maintenance requirements.

It is an object of the sealing strip for sealing head-of-wall joints of the present invention to expedite installation and minimize labor costs.

Many patents have been applied or granted for various constructions for insulating head-of-wall joints as described above such as shown in U.S. Patent Application Publication No. 2011/247281 A1 published Oct. 13, 2011 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL CONSTRUCTION PRODUCT”; U.S. Patent Application Publication No. 2013/031856 A1 published Feb. 7, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL CONSTRUCTION PRODUCT”; U.S. Pat. No. 8,281,552 B2 patented Oct. 9, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “EXTERIOR WALL CONSTRUCTION PRODUCT”; U.S. Pat. No. 8,499,512 B2 patented Aug. 6, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “EXTERIOR WALL CONSTRUCTION PRODUCT”; U.S. Patent Application Publication No. 2013/0086859 A1 published Apr. 11, 2013 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,617,643 B2 patented Nov. 17, 2009 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,950,198 B2 patented May 31, 2011 to Donald A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 8,087,205 B2 patented Jan. 3, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 8,322,094 B2 patented Dec. 4, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “FIRE-RATED WALL AND CEILING SYSTEM”; U.S. Pat. No. 7,752,817 B2 patented Jul. 13, 2010 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,132,376 B2 patented Mar. 13, 2012 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,413,394 B2 patented Apr. 9, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Pat. No. 8,555,566 B2 patented Oct. 15, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “TWO-PIECE TRACK SYSTEM”; U.S. Patent Application Publication No. 2011/214371 A1 published Sep. 8, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “OFFSET LEG FRAMING ELEMENT FOR FIRE STOP APPLICATIONS”; U.S. Pat. No. 8,468,759 B1 patented Jun. 25, 2013 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “FIRE RETARDANT COVER FOR FLUTED ROOF DECK”; U.S. Patent Application Publication No. 2011/146180 A1 published Jun. 23, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on an “ACOUSTICAL AND FIRESTOP RATED TRACK FOR WALL ASSEMBLIES HAVING RESILIENT CHANNEL MEMBERS”; U.S. Patent Application Publication No. 2011/167742 A1 published Jul. 14, 2011 to James A. Klein assigned to Blazeframe Ind. Ltd. on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 7,681,365 B2 patented Mar. 23, 2010 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 7,814,718 B2 patented Oct. 19, 2010 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS”; U.S. Pat. No. 7,866,108 B2 patented Jan. 11, 2011 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,056,293 B2 patented Nov. 15, 2011 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,136,314 B2 patented Mar. 20, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS”; U.S. Pat. No. 8,151,526 B2 patented Apr. 10, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES”; U.S. Patent Application Publication No. 2012/0297710 A1 published Nov. 29, 2012 to James A. Klein on “CONTROL JOINT BACKER AND SUPPORT MEMBER ASSOCIATED WITH STRUCTURAL ASSEMBLIES”; U.S. Patent Application Publication No. 2011/0099928 A1 published May 5, 2011 to James A. Klein and Alastair Malcolm on “DEFELCTION AND DRIFT STRUCTURAL WALL ASSEMBLIES”; CA Patent Application Publication No. 2550201 A1 published Dec. 15, 2007 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS AND RELATED WALL ASSEMBLIES”; U.S. Pat. No. 8,181,404 B2 patented May 22, 2012 to James A. Klein on “HEAD-OF-WALL FIREBLOCKS AND RELATED WALL ASSEMBLIES”; U.S. Patent Application Publication No. 2013/0186020 A1 published Jul. 25, 2013 to Don A. Pilz assigned to California Expanded Metal Products Company on a “FIRE-RATED JOINT SYSTEM”; U.S. Pat. No. 8,353,139 B2 patented Jan. 15, 2013 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “WALL GAP FIRE BLOCK DEVICE, SYSTEM AND METHOD”; U.S. Patent Application Publication No. 2013/118102 A1 published May 19, 2011 to Don A. Pilz et al. assigned to California Expanded Metal Products Company on a “WALL GAP FIRE BLOCK DEVICE; SYSTEM AND METHOD”; U.S. Patent Application Publication No. 2013/205694 A1 published Aug. 15, 2013 to James P. Stahl assigned to Specified Technologies Inc. on “INSULATING GASKET CONSTRUCTION FOR HEAD-OF-WALL JOINTS”; U.S. Pat. No. 8,375,666 B2 patented Feb. 19, 2013 to James P. Stahl et al assigned to Specified Technologies Inc. on “FIRESTOPPING SEALING MEANS FOR USE WITH GYPSUM WALLBOARD IN HEAD-OF-WALL CONSTRUCTION”; U.S. Patent Application Publication No. 2013/091790 A1 published Apr. 18, 2013 to James P. Stahl et al. assigned to Specified Technologies Inc. on “FIRESTOPPING MEANS FOR USE WITH GYPSUM WALLBOARD IN HEAD-OF-WALL CONSTRUCTION”; U.S. Pat. No. 7,240,905 B2 patented Jul. 10, 2007 to James P. Stahl on “METHOD AND APPARATUS FOR SEALING A JOINT GAP BETWEEN TWO INDEPENDENTLY MOVABLE STRUCTURAL SUBSTRATES”; U.S. Pat. No. 6,698,146 B2 patented Mar. 2, 2004 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 6,783,345 B2 patented Aug. 31, 2004 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 7,043,880 B2 patented May 16, 2006 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 7,152,385 B2 patented Dec. 26, 2006 to Michael D. Morgan et al. assigned to W.R. Grace & Co.-Conn. on “IN SITU MOLDED THERMAL BARRIERS”; U.S. Pat. No. 5,010,702 patented Apr. 30, 1991 to T. L. Daw et al and assigned to Daw Technologies, Inc. on a “Modular Wall System”; and U.S. Pat. No. 5,127,203 patented Jul. 7, 1992 to R. F. Paquette on a “Seismic/Fire Resistant Wall Structure and Method”; and U.S. Pat. No. 5,755,066 patented May 26, 1998 to D. W. Becker on a “Slip Track Assembly; and U.S. Pat. No. 5,913,788 patented Jun. 22, 1999 to T. R. Herren on a “Fire Blocking And Seismic Resistant Wall Structure”; and U.S. Pat. No. 5,921,041 patented Jul. 13, 1999 to J. D. Egri, II on a “Bottom Track For Wall Assembly”; and U.S. Pat. No. 5,950,385 patented Sep. 14, 1999 to T. R. Herren on an “Interior Shaft Wall Construction”; and U.S. Pat. No. 6,058,668 patented May 9, 2000 to T. R. Herren on a “Seismic And Fire-Resistant Head-of-Wall Structure”; and U.S. Pat. No. 6,176,053 patented Jan. 23, 2001 to Roger C. A. St. Germain and assigned to Robert C. A. St. Germain on a “Wall Track Assembly And Method For Installing The Same”.

Although the known fire block header tracks provide exceptional performance, there still exists a need for fire block arrangements that can be applied to any desired structure, such as the wall, floor or ceiling of a building construction or to the stud wall assembly and to header tracks. Furthermore, as described herein, alternative embodiments of the wall gap fire blocks can be applied to a wall bottom track to protect a foot-of-wall gap or a (vertical or horizontal) gap in a location other than the head or foot of a wall. The present fire blocks are well-suited to application on the job site.

Preferred embodiments of the present invention provide an adhesive sealing strip (herein also referred to as sealing strip) that can be applied to a header track or other head-of-wall structure to create a head-of-wall insulation block, including, fire block. The adhesive sealing strip may include strip portions of another material, among other material portions, if desired.

In brief, the present invention is directed in general to a fire retardant head-of-wall assembly configured to seal a linear construction joint or gap when exposed to a heat source, such as in the event of fire. In more detail the present invention is directed to (firestopping) sealing means for use with dry wallboard, i.e., gypsum wallboard, in a head-of-wall or similar construction comprising a cover material strip (herein also referred to as cover layer), in particular an elongated cover material strip, an adhesive layer, and optionally an insulating material layer (herein also referred to as insulating layer) or spacer. The sealing strip being positioned on at least one portion of the leg of the track, the upper portion of the track, which is in abutment with the construction element to which the track is fixed, and on the construction element to cover the gap or joint between the track and the construction element, whereas the insulating material strip only in some embodiments will be affixed on the construction element.

The sealing strip of the present invention can be applied to any joint or gap between construction elements of any kind, e.g., wall to wall joints, wall to floor joints, wall to ceiling joints, joints between construction elements such as floor, wall, or ceiling, which are also referred to as support structure, and construction elements other than the support structures such as dry wall assemblies, in particular to the tracks, i.e., bottom and header track. For a better understanding, the invention will be described in view of the joint between an element of a dry wall assembly, e.g., the track, in particular header track, and a support structure, e.g., the ceiling, to which the track is fixed. This however shall not be understood to limit the scope of the invention.

After the sealing strip is being brought into its desired positioned near the track, i.e., the sealing strip is fixed to the construction element, e.g., the wall or ceiling, and the dry wall assembly, e.g., the header or floor track by the adhesion layer, the cover layer, will constitute the outer surface of the material. The cover layer will come into contact with the wallboard or similar construction element.

The sealing strip comprises a cover material strip and an adhesive layer that covers the cover material strip at least partially to secure the sealing strip to the ceiling (overhead structure) and the header track. The sealing strip is installed lengthwise along the joint and will preferably be fixed on the ceiling and on the track between which the joint forms. In some cases it is also possible to fix the sealing strip on only one of the construction elements.

In a preferred embodiment the sealing strip is an elongated strip to be positioned lengthwise at the leg of the header track. The width of the elongated strip depends on the height of the legs and is selected such that the sealing strip covers the area of the ceiling next to the track and only part of the leg, in particular the upper part of the leg. Preferably, the sealing strip is designed as an endless strip having two opposing lateral edges (side edges) and two opposing end edges, i.e., the back edge and the front edge, whereas the side edges are arranged parallel with the gap or joint to which the sealing strip will be applied.

The cover material layer provides a firestop means to sufficiently seal the joint between the header track and the ceiling, against fire to prevent the penetration of fire and in some embodiments also of smoke for a given period of time.

Therefore, the cover layer is made of non-combustible, i.e., fire resistant, material. The cover layer can be made of a fabric, which fabric comprises inorganic fibers such as fibers made of glass, stone, ceramic and/or metal or any other suitable material, in particular glass fibers. Alternatively, the cover layer can be an inorganic film material, like metal films or any other suitable film material, in particular metal films, e.g., aluminum foil having a thickness of about 20 to 50 microns (20-50 μm). It is also possible that the cover layer comprises a combination of inorganic fibers and an inorganic film material, e.g., a layer made of inorganic fibers such as glass fibers, and a further layer (coat layer) made of an inorganic film material such as an aluminum foil.

To enhance the inherent (dimensional) stability and to increase the mechanical strength of the cover layer, in particular when the fabric consists essentially of glass, stone or ceramic fibers, the fabric may contain weft thin metal wires. Preferably, the metal wires are woven into the fabric in a direction perpendicular to the length of the strip to provide superior dimensional stability.

The cover layer preferably is abrasive-resistant to resist abrasion caused by the gypsum wall member of the dry wall assembly rubbing against the sealing strip when moving up and down due to movement of the building. The optional weft metal wires enhance the abrasive-resistant properties.

To fix the sealing strip either on the ceiling or on the leg of the track or on both, the sealing strip also comprises at least one adhesive layer. In the simplest embodiment the sealing strip consists of the cover layer which is provided on one side with an adhesion layer that completely covers one surface of the cover layer.

The adhesive layer is not restricted to any particular material provided that it provides sufficient adhesion to constructional elements made of various materials, like concrete, brick, wood, metal and the like. The adhesive layer can consists of material that does not lose its adhesive power at elevated temperatures. Alternatively, the adhesive layer can be any conventional adhesive for applications on constructional materials, such as concrete and steel, e.g., acrylic adhesives, or a self-adhesive putty material, such as rubber, e.g., polyisobutylene based rubber, bitumen or the like. These adhesives are all commercially available. It is also possible to apply different adhesives to the cover layer, e.g., a high temperature resistant adhesive applied on that portion of the cover layer which will be fixed on the ceiling and another adhesive not being high temperature resistant applied on the portion of the cover layer which will fixed on the leg of the track. The adhesive layer can be applied as a layer or as strips separated from each other.

Preferably a removable protective layer covers the adhesive layer until the insulating strip is ready to be applied.

In one embodiment, in particular where the cover layer comprises a fabric made of non-combustible (fire resistant) fibers made of glass, stone, ceramic or the like, and therefore only partly stays in form when bent in the longitudinal direction to better fit the joint between the track and the ceiling, the sealing strip contains a predefined flexing or bending point, such as a movement pleat or kink (herein referred to as flexing point). The flexing point can, for example, be provided by a material weakness. The material weakness can be achieved, for example, by folding the cover layer to result in the flexing or bending point. For this, one side edge or both side edges of the cover layer is/are folded up to result in a portion/portions of the cover layer that has/have a cover double layer. When both side edges of the cover layer are folded up, the folded parts may be symmetrical if both resulting cover double layers are of the same size (symmetrical folding). The joint edges of the folded cover layer will then form the flexing point. Alternatively, the folded parts may be asymmetrical if the resulting cover double layers have a different size (asymmetrical folding). Again, the joint edges of the cover layer will then form the flexing point. The symmetrical folded cover layer enables the user to install the sealing strip from any side but the portion of the sealing strip which will be fixed to the ceiling might extend beyond the wallboard. If the sealing strip shall not be visible after the wallboard is installed, the asymmetrical folded cover layer is preferred, whereas the smaller part will be positioned on the ceiling and the larger part will be positioned on the leg. When only one side edge of the cover layer is folded up, the cover is folded asymmetrical. The side edge which is folded up then forms the flexing point.

To adapt the sealing strip to better fit in the corner between the track and the ceiling, the sealing strip can either show one portion of a folded cover layer, i.e., that portion which will be fixed at the construction element, or that portion which will be fixed on the track, or two portions, i.e., both the portion which will be fixed at the construction element and the portion which will be fixed on the track, so that the flexing or bending point matches the corner, i.e., gap between the construction element and the track. This will assure a precise installation of the sealing strip and enables a perfect fitting installation at the gap or joint.

Folding the cover layer additionally provides an edge protection to prevent frayed edges and sharp edges resulting from the weft metal wires. This contributes to the safety and the quality of the sealing strip.

In a preferred embodiment, the folded portions of the cover layer are secured by an additional adhesive between the folded portions which are in contact with each other. This prevents unwanted and unintentional unfolding of the folded (superimposed) layers. The additional adhesive further enhances the mechanical strength of the sealing strip, in particular in case the cover layer is made of a material other than a metal foil, metal fabric or metal reinforced fabric. However, this also simplifies the handling and installation of the sealing strip.

In case the sealing strip comprises only one portion where the side edges of the cover layer is folded inwardly to provide one portion with a single cover layer and one portion with a double cover layer, the adhesive to secure the double cover layer may also form part of the adhesive layer with which the single cover layer is fixed to the construction element, e.g., the ceiling. For this, the adhesive will be applied to one entire surface of the cover layer and then one side edge of the cover layer will partly be folded inwardly.

In one aspect of the invention the sealing strip comprises a cover layer and an adhesive layer. The dimension of the sealing strip shall be selected such that sufficient adhesion to the ceiling and the track will be assured. But, for improved appearance the sealing strip shall not extend beyond the joint, i.e., when mounted on the construction element, e.g., ceiling, the cover layer shall not extend beyond the wallboard member and thus shall not be visible after the wallboard member is mounted. For easier inspection it, however, could be necessary that the sealing strip extends beyond the joint to be visible after installing the dry wall.

With a first portion of the cover layer the sealing strip of the first aspect of the invention will be fixed to the ceiling. With a second portion of the cover layer the sealing strip of the first aspect of the invention will also be fixed to the leg of the track, in particular the upper part of the leg. For this an adhesive layer is used with which both portions of the cover layer are fixed to the construction elements.

The first portion or the second portion of the cover layer or both portions of the cover layer may show two layers, wherein each loose side edge of the cover layer is folded inward. This results in a flexing point or bending point, which more or less is a flexing line or bending line extending in the longitudinal direction. The flexing line or bending line will then cover the gap or joint between the track and the respective construction element.

The sealing strip can be applied to solid and slotted tracks of a dry wall assembly, preferably to solid tracks. When used with slotted tracks, the sealing strip is preferably adapted to the structure of the slotted track.

Therefore, in another embodiment the sealing element to be particularly used with slotted tracks additionally comprises a spacer or additional insulating element. In this embodiment, the sealing strip preferably covers the entire leg of the track. The sealing strip is preferably designed such that the additional insulating element or the additional spacer is positioned on the bottom part of the leg to align with that portion of the leg beneath the slots so that the slots are entirely covered by the sealing strip. In this embodiment, that portion of the sealing element covering the leg of the track will be fixed on the track below the slots. The thickness of the additional insulating element or spacer corresponds to the size, in particular height, of the screw heads used for securing the studs to the track. The screws can freely move between the track and the cover layer. It is also possible that the additional insulating element or spacer extends over the width of the leg.

In a preferred embodiment of the sealing strip, the additional sealing element or spacer is enveloped by the cover layer, i.e., is positioned between a double cover layer. This is particularly important in case the additional sealing element or spacer extends over the entire leg of the track to protect the additional insulating element or spacer against damage caused by the screw and to resist abrasion caused by the wall member rubbing against the insulating material when moving up and down to due movement of the building.

The material of the additional insulating element or spacer is not limited. It may provide additional fire protection or sound insulation. The additional insulating element may comprise non-intumescent and/or intumescent materials. An intumescent material will be used if enhanced sealing in the event of fire is intended. The intumescent material may be constructed partially or entirely from an intumescent material such as CP 646 from Hilti, for example. It is also possible for the insulating material of the present invention to have components of both intumescent and acoustical sealing therewithin. It is particularly preferred that the insulating material includes an intumescent material only. When the temperature rises the intumescent material will expand quickly and block air pathways.

An acoustical insulating material is intended for applications where sealing against sound transmissions is found to be desirable. Such acoustical insulating configurations can preferably be formed of a felt acoustical insulating material. Alternatively, it can be formed of a foamed insulating material which can easily be provided with intumescent properties by including intumescent additives.

In one embodiment the additional insulating element or the spacer may be constructed partially or entirely from a compressible material such as plasticines, fabric (non-woven or woven) or a felt, e.g., glass fiber braid, glass fiber fabric or glass fiber mat. Plasticines, which are also referred to as putties, are frequently used for this application. They generally consist of a liquid polymer such as butyl rubber, plasticizers (paraffin oil, phthalates, adipates, etc.) and fillers, with a filler content of up to 80 percent. In particular the plasticine contains, as liquid polymer, at least one representative of the group comprising polyurethanes, polyvinyl acetates, polyvinyl ethers, polyvinyl propionates, polystyrenes, natural or synthetic rubbers, poly((meth)acrylates) and homopolymers and copolymers based on (meth) acrylates, acrylonitrile, vinyl esters, vinyl ethers, vinyl chloride and/or styrene, preferably poly(alkyl methacrylate), poly(alkyl acrylate), poly(aryl methacrylate), poly(aryl acrylate) and/or copolymers thereof with n-butyl acrylate and/or styrene. The plasticine may comprise fire-protection additives. In this regard reference is made to the U.S. patent application No. 2005/032934 A1 which is incorporated in its entirety herein by reference.

In another, preferred embodiment, the additional insulating element or the spacer may be constructed partially or entirely from a pressure-resistant material such as acrylate based polymer or a hard putty such as rubber, e.g., polyisobutylene based rubber. These materials may comprise a reinforcing member such as glass fibers or a glass fiber fabric to enhance strength of the material. The term “pressure-resistant” means that while installing the wallboard, the material shall be deformed only slightly so that in case of vertical movement of the wallboard tilting and entanglement of the insulating material are always avoided.

In all embodiments described above two sealing strips are necessary to seal the joint on both sides of the track.

In another alternative embodiment the sealing strip may by designed such that the joint on both sides of the track will be sealed with a single sealing strip.

In this embodiment the cover layer, which is an elongated layer, is designed as a continuous strip defining two faces, an upper and a bottom face. The width of the continuous strip is selected depending on the size of the header track or other construction product to which the insulating strip shall be attached. The continuous strip defines a middle section which extends generally horizontally and which will be positioned on the web of the header track and defines side sections (hereinafter also referred to as first and second side sections), so that the total width of the tape is larger than the width of the web. While installing the insulating strip the side sections shall cover both flanges of the header track or other head-of-wall structure. To provide double layered cover layers on each leg, the width of the side sections of the cover layer correspond to at least twice the width of leg. To provide flexing points, the side edges are folded inwardly to obtain double layered side sections that cover the leg. If an additional insulating element or a spacer is positioned between the double layers the width of the side sections is adapted correspondingly.

The sealing strip will be mounted on the track such that the additional insulating elements or spacer on the first and second side section will face towards the leg of the track and will be positioned in the lower part of the leg. With this the upper part of the legs and the web is free of any insulating material and will only be covered by the cover layer. Preferably, the two insulating additional elements or spacers are located near the lower edges of the leg distal from the web to have a maximum distance between each other.

For enhanced acoustic or smoke sealing a further additional insulating element can be positioned on the portion of the cover layer that covers the web of the track. Preferably, the further additional insulating element will face towards the ceiling.

The above-described and other features, aspects and advantages of the present invention are described below with reference to drawings of preferred embodiments, which are intended to illustrate, but not to limit, the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a portion of a stud wall assembly with a sealing strip installed at the head-of-wall according to one embodiment of the invention;

FIG. 2 shows a schematic sectional view of a sealing strip according to the exemplary embodiment of FIG. 1;

FIG. 3 is a cross-sectional view of a portion of a stud wall assembly with a sealing strip installed at the head-of-wall according to another embodiment of the invention;

FIG. 4 shows a schematic sectional view of a sealing strip according to the exemplary embodiment of FIG. 3;

FIG. 5 is a cross-sectional view of a portion of a stud wall assembly with slotted tracks and with a sealing strip installed at the head-of-wall according to another embodiment of the invention;

FIG. 6 is a cross-sectional view of a portion of a stud wall assembly with slotted tracks and with a sealing strip installed at the head-of-wall according to another embodiment of the invention; and

FIG. 7 is a cross-sectional view of a portion of a stud wall assembly with slotted tracks and with a sealing strip installed at the head-of-wall according to another embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS. 1, 3, 5 and 6 illustrate various embodiments of the sealing strip 1 of the invention to the dry wall assembly. The dry wall assembly comprises a header track 20 with a web 21, legs 22, wallboards 23 and studs (not shown). The header track is a U-shaped channel that is attached to an upper horizontal support structure 10 (also referred to as overhead structure 10). Wall studs (not shown) are received in the header track 20 and may be configured for vertical movement relative to the header track 20. A wallboard 23 is attached to the studs such as by a plurality of suitable fasteners.

As shown in more detail in FIG. 2, the sealing strip 1, in particular an elongated strip, according to the first embodiment of the invention comprises a cover layer 2, an adhesive layer 3 shown by the dashed line, an additional adhesive layer 5 and a flexing point indicated by the line 4. The flexing point 4 is achieved by asymmetrically folding the cover layer 2. This results in two asymmetric portions with double layered portions of the cover layer, one smaller portion shown on the left hand side of the flexing point 4 and the other shown on the right hand side of the flexing point 4. The folded areas of the cover layer 2 are fixed by the additional adhesive layer 5 to prevent unintended unfolding of the double layers.

As shown in FIG. 1 the sealing strip 1 is affixed on the ceiling with the smaller portion of the folded cover layer 2 (see FIG. 2) by the adhesive layer 3 (not shown in FIG. 1) and on the upper part of the solid leg 22 with the larger portion of the folded cover layer 2 (see FIG. 2) by the adhesive layer 3 (not shown in FIG. 1). The sealing strip is installed so that the flexing point 4 (see FIG. 2) is located near the joint between the track 20 and the ceiling 10.

The cover layer 2 supports movement of the wallboard 23. Since the larger portion of the cover layer 2 (see FIG. 2) is fixed on the solid leg 22 by the adhesive layer 3, the sealing strip will stay in place and will not follow the movement of the wallboard 23.

Another embodiment of the sealing strip 1 of the present invention is shown in FIG. 4. This embodiment is very similar to the one shown in FIG. 2 with the difference that only one side of the cover layer 2 is asymmetrically folded inwardly. The sealing strip 1 according to the embodiment shown in FIG. 4 comprises a cover layer 2, an adhesive layer 3 shown by the dashed line, an additional adhesive layer 5 and a flexing point indicated by the line 4. The flexing point 4 is achieved by asymmetrically folding only one edge of the cover layer 2. This results in two asymmetric portions, one smaller portion shown on the left hand side of the flexing point 4 with a single layered portion of the cover layer 2 and the other shown on the right hand side of the flexing point 4 with a double layered portion of the cover layer 2. The folded area of the cover layer 2 is fixed by the additional adhesive layer 5 to prevent unintended unfolding of the double layers. The additional adhesive layer 5 on the left hand side of the flexing point 4 functions as adhesive to fix the sealing strip on the ceiling as shown in FIG. 3.

As shown in FIG. 3 the sealing strip 1 is affixed on the ceiling with the smaller portion of the single layered portion of the cover layer 2 (see FIG. 4) by the adhesive layer 5 (not shown in FIG. 3) and on the upper part of the leg 22 with the larger double layered portion of the cover layer 2 (see FIG. 4) by the adhesive layer 3 (not shown in FIG. 3). The sealing strip 1 is installed so that the flexing point 4 (see FIG. 4) is located near the joint between the track 20 and the ceiling 10.

The sealing strip 1 shown in FIGS. 3 and 4 will be installed the same way as described for the sealing strip 1 shown in FIGS. 1 and 2.

FIG. 5 shows the sealing strip 1 designed to be used with slotted tracks. The slots 24 are shown as brighter areas in the legs 22. The sealing strip 1 of this embodiment is very similar to the one shown in FIGS. 1 and 2 with the difference that in the larger portion of the folded cover layer 2 to be fixed to the leg 22 an additional insulating element 6 is positioned between the two layers. In this area the cover layer 2 almost completely wraps the additional insulating element 6.

FIG. 6 shows an alternative embodiment of the sealing strip 1 designed to be used with slotted tracks. The sealing strip 1 shown is very similar to the one shown in FIG. 5 with the difference that the additional sealing element 6 has a smaller size. With this, the additional sealing element 6 is completely wrapped by the double layer portion of the cover layer 2 which is fixed to the leg 22. The additional sealing element 6 is positioned on the lower portion of the leg 22 and is fixed below the slots 24. As a result, the slots 24 are completely covered by the insulating strip 1.

In both the embodiments shown in FIGS. 5 and 6 the width of the additional sealing element 6 is adapted to the size in particular the height of the heads of the screws (not shown) so that the screws can move without damaging the sealing strip 1.

FIG. 7 illustrates the sealing strip 1 according to another embodiment of the invention applied to a head-of-wall structure, in particular to a slotted header track 20. The sealing strip 1 comprises two additional insulating elements 6. The insulating strip 1 is attached to the header track 20 so that a portion, i.e., the middle section, is positioned between the header track 20 and the ceiling 10 and another portion, i.e., the side sections containing the additional insulating elements 6, is positioned between the legs 22 and the wallboard 23. The additional sealing elements 6 are completely wrapped by the double layered side portions of the cover layer 2 which are fixed to the leg 22. The additional sealing elements 6 are positioned on the lower portions of the legs 22 and are fixed below the slots 24. As a result, the slots 24 are completely covered by the insulating strip 1.

To enhance acoustic insulation and/or fire protection, the embodiment shown in FIG. 7 additionally comprises an insulating layer 7 which is fixed to the cover layer of the sealing element by an intumescent layer 9. The insulating layer 7 faces the ceiling 10 structure to better adapt to an uneven contour of the ceiling 10.

While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.

The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be constructed to include everything within the scope of the appended claims and equivalents thereof. 

What is claimed is:
 1. A sealing element for sealing a gap or joint between a support structure and a track, wherein the track includes a web and legs that extend vertically from the web, comprising: a cover layer; wherein the cover layer has a first portion that is adhesively attached to the support structure; wherein the cover layer has a second portion that is adhesively attached to a leg of the track; wherein the cover layer has a flexing point; and wherein the flexing point is disposed near a gap or joint between the support structure and the leg of the track.
 2. The sealing element according to claim 1, wherein the flexing point is formed by a first folded side edge and a second folded side edge of the cover layer.
 3. The sealing element according to claim 2, wherein the first folded side edge and the second folded side edge are symmetrical.
 4. The sealing element according to claim 2, wherein the first folded side edge and the second folded side edge are asymmetrical.
 5. The sealing element according to claim 4, wherein the first folded side edge is smaller than the second folded side edge and wherein the first folded side edge is attached to the support structure and the second folded side edge is attached to the leg of the track.
 6. The sealing element according to claim 1, wherein the flexing point is formed by a single folded side edge of the cover layer.
 7. The sealing element according to claim 1, wherein the leg of the track has a slot, wherein the second portion of the cover layer extends along an entire length of the leg of the track, and wherein the second portion of the cover layer includes an insulating element.
 8. The sealing element according to claim 7, wherein the second portion of the cover layer envelops the insulating element.
 9. The sealing element according to claim 7, wherein the insulating element is an intumescent material.
 10. The sealing element according to claim 7, wherein the insulating element is an acoustical insulating material.
 11. The sealing element according to claim 7, wherein the insulating element is a pressure-resistant material.
 12. The sealing element according to claim 7, wherein the insulating element is disposed only on an end of the leg of the track, wherein the end of the leg of the track is opposite from an end of the leg of the track that is disposed adjacent to the support structure.
 13. The sealing element according to claim 1, wherein the cover layer includes a first insulating element and a second insulating element, wherein the first insulating element is disposed on the leg of the track, and wherein the second insulating element is disposed on a second leg of the track.
 14. The sealing element according to claim 13, wherein the leg of the track has a first slot, wherein the second leg of the track has a second slot, and wherein the cover layer extends along an entire length of the track.
 15. The sealing element according to claim 14, further comprising an insulating layer attached to the cover layer.
 16. The sealing element according to claim 14, further comprising an intumescent layer attached to the cover layer.
 17. The sealing element according to claim 13, wherein the first insulating element is disposed only on an end of the leg of the track, wherein the second insulating element is disposed only on an end of the second leg of the track, wherein the ends of the leg and second leg of the track are opposite from respective ends of the leg and second leg of the track that are disposed adjacent to the support structure.
 18. The sealing element according to claim 13, wherein the cover layer envelops the first insulating element and the second insulating element. 